Whirling Machine. New Dimension of Whirling Technology. Thread Whirling Machines. Big Workpiece Diameter. High Pitch Thread

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1 LEISTRITZ PRODUKTIONSTECHNIK GMBH Thread Whirling Machines Whirling Machine New Dimension of Whirling Technology Big Workpiece Diameter High Pitch Thread

2 Customer Satisfaction remains the Highest Priority The design for the completely new developed Leistritz LWN 190 / LWN 300 whirling machines were a result out of the requests from our customers to produce screws with even larger pitch and helix angle and market demands. LEISTRITZ is the worldwide leading manufacturer of whirling machines providing turn-key packages including machine, tooling, programming and application specific know-how. Performance Characteristics Increased machine capacity Machining of hard and soft materials Extremely high chip removal rates Minimal dwell times for shorter chip-to-chip rates Dry and wet machining Machining to finish tolerances Fanuc 18 TB Siemens 840 D 2

3 LEISTRITZ PRODUKTIONSTECHNIK GMBH New Spindle Drive System For the whirling unit drive of the LWN 190 / LWN 300 a high performance rated torque-motor will be used. This drive has the ability to provide a high torque necessary for heavy cutting and offers easy maintenance. The high spindle speed permits faster cutting speeds which improves surface roughness of the workpiece while reducing cycle time. Whirling Unit The new designed whirling unit AWS II / AWS III is able to machine screw profiles with helix angles up to ± 50. Whirling Unit AWS III with a detail of AWS II Highest Workpiece Quality Thermal Stability The complete whirling unit is temperature-controlled to guarantee highest stability during heavy cutting process and to provide improved profile accuracy during finish cutting. Stiffness - Vibration damping polymer concrete filled machine bed - Special design of the steady rests providing very rigid and precise support of the workpiece - Widened X-axis guideways providing greater stiffness and accuracy Economic Performance LEISTRITZ has developed a new rapid clamping system for the whirling ring which reduces the dwell time to less than 2 minutes. The new torque-motor drive system allows full optimization of the cutting speed and therefore increasing the efficiency of the machining operation. Fast Clamping System LEISTRITZ has developed new insert material and coatings to improve tool life to reduce the cost per workpiece. 3

4 Components and Options Headstock The housing of the headstock is a massive welded design. The hollow main spindle is supported by high precision, preloaded spindle bearings and driven by a AC servo motor. Position feedback via a direct mounted absolute encoder for the most precise and state-of-the-art system. Loading through the spindle is possible. Support Rests The LWN 190 / LWN 300 are equipped with massive workpiece supports for carrying the weight of large workpieces and eliminate any deflection or bending. Each rest is driven by a AC servo motor with integrated drive mechanism and ballscrew actuation. These improved units have a positioning accuracy of 0.01mm. Clamping Chuck Depending on the application, a wide variety of clamping solutions are available: A 3-jaw manual chuck for standard applications Adjustable 3-jaw chuck with high repeatability Hydraulic actuated collet chuck Hydraulic actuated 3-jaw chuck for applications requiring highest concentricity and runout accuracy Support Rests Nearly all possibilities are available to mount various chucks to the standard spindle nose. Special functions like clamping stroke monitoring or length end stop can be integrated. 4

5 LEISTRITZ PRODUKTIONSTECHNIK GMBH Longitudinal Slide (Z-axis) The very stiff and wide linear guideways of the Z-axis slide guarantee an exact and friction free guidance. The guideways are completely protected by a steel-telescopic guarding system. Machine Enclosure The machine is equipped with an ergonomically designed cover that permits wet and dry machining. The cover also protects the machine operator by preventing in-process opening of the sliding door. The safety glass window and worklight provide good observation of the whirling operation. Tailstock (optional) The CNC controlled tailstock is easy to maintain. It provides a highly adjustable, rigid and accurate support at the end of long workpieces using the constant torque feature of the CNC-control. Peeling Head AWE (optional) For producing single lobe, eccentric progressive cavity pump rotors resp. eccentric screw pump rotors, LEISTRITZ designed a high powered rigid whirling head type AWE. The AWE is ideal for high production, heavy cutting peeling operations. Machine Enclosure Tailstock 5

6 Tool Systems Whirling Ring Fast clamping system This new development guarantees a fast and easy exchanging of the whirling ring. Soft Material Machining The Leistritz patented, tangential tool system which uses re-grinding carbide inserts has proven itself to be the most economic solution for soft machining operations. It totally eliminates the need for complicated and expensive setting of the tools while in the machine. Each insert has a layer of re-surfacing material. Hard Steel Machining LEISTRITZ also has a solution for whirling hardened material up to 64 HRC. With the LEISTRITZ radial design whirling ring, precision screws, such as ballscrews are whirled to finish tolerances. To keep the tool costs per piece low, each insert can be re-ground by profile grinding. Application Area of the LWN 190 / LWN 300 Screw Pump Rotors Single and Multi Lobe Progressive Cavity Pump Rotors Workpiece Capacity LWN 190 Injection Mold and Extruder Screws Ball Screws workpiece diameter: ø mm workpiece length: acc. to customer requirement material up to 64 HRC LWN 300 workpiece diameter: ø mm workpiece length: acc. to customer requirement material up to 64 HRC 6

7 LEISTRITZ PRODUKTIONSTECHNIK GMBH General Machine Specifications LWN 190/ LWN 300 Machine dimension with guarding and electrical panel Without chip conveyor (LxWxH) approx.: 8,000 mm x 1,900 mm x 2,240 mm Machine weight with guarding, electrical panel and chip conveyor approx. 32,000 kg H W L Technical Data LWN 190 LWN 300 Headstock (C-axis) Spindle through-bore ø 104 mm ø 130 mm (may be reduced depending on chuck type) Spindle Nose (for chuck acc. DIN 6353) ø 120 mm ø 220 mm Resolution of the C-axis ± 0.01 ± 0.01 Tailstock (T-axis) Axial force max. 5,100 N 5,100 N (Completely adjustable via the CNC program) Positioning Accuracy ± mm ± mm Steady Rests: ZSL ZSL Stroke max. 80 mm 150 mm Clamping Range ø mm ø mm steady rest jaw sizes: 2 3 Clamping Force 800-8,500 N 800-8,500 N Longitudinal Axis (Z-axis) Travel depending on machine size depending on machine size Axial Force max. 11,800 N 11,800 N Positioning Accuracy ± mm ± mm Cross Slide (X axis) Axial Force max. 22,000 N 22,000 N Positioning Accuracy ± mm ± mm External Whirling Unit: AWS II AWS III Through-Hole (without tooling) ø 190 mm ø 340 mm Speed Range 600-4,500 rpm 250-1,000 rpm Drive Type Torque - Motor Torque - Motor Power max KW 26 KW Helix Angle Adjustment (A-axis) Travel ± 50 ± 50 Positioning Accuracy CNC Control Siemens 840 D / Fanuc 18 TB Electrical Supply Voltage (other voltages available) 400 VAC ± 10 % 400 VAC ± 10 % Frequency 50 Hz ± 2 % 50 Hz ± 2 % Main Fuse 40 A 160 A Total Connected Load 40 kva 110 kva Control Voltage 24 VDC 24 VDC Technical alterations reserved 7

8 Leistritz Product-Range of Whirling Machines The perfect machine solution for each application LWN 65 Small gear worms bone screws LWN 90 Steering worms gear worms LWN 120 Gear worms mini ball-screws bone screws EPS worms small eccentric screws small pump screws rack and pinion spindles LWN 160 Ball screw spindles spindles eccenteric worms LWN 190 LWN 300 LWN 300 PM INNOVATION 200 Pump screws eccenteric worms ball screw spindles plastification worms Cavity pump rotors single and multi-lobe rotors for downhole motors Complete and hard machining of thread nuts Partner for modern Technology LEISTRITZ PRODUKTIONSTECHNIK GMBH PO BOX D Nuremberg Phone: +49 (0) 911/ Fax: +49 (0) 911/ Internet: Factory Pleystein: Leistritzstrasse 1-11 D Pleystein Phone: +49 (0) 9654/ 89-0 Fax: +49 (0) 9654/ LEISTRITZ CORPORATION Allendale NJ Chestnut Street Phone: / Fax: / LEISTRITZ NIPPON CORPORATION Tenma Hachikenya Bldg. 3F, Kitahama Higashi 2-12, Chuouku, Osaka /Japan Phone: +81 6/ Fax: +81 6/ LEISTRITZ MACHINERY (TAICANG) CO., LTD. 3/Floor, R , 98 Shanghai Road (East), Taicang,Economy Development Area, Jiangsu , China Phone: Fax: Mobile: e 02/11 1` tü